Process for the continuous polymerization with micromixing of reactive fluids

ABSTRACT

The process for the continuous preparation of homopolymers or copolymers by free-impinging-jet micromixing of fluids formed ( 1 ) of monomer(s) and ( 2 ) of an initiator system consists in micromixing the said fluids ( 1 ) and ( 2 ) and in recovering the mixture of these fluids in the form of a resultant jet Jr, originating from the point of impingement (I), the micromixture being obtained by:
         a) forming at least one group of at least two jets Ja of the said identical or different fluids, these jets coinciding at a point of impingement (I), the jets Ja of the same group all being of identical geometry, their axes being arranged such that their projections on a plane perpendicular to the axis (A) of the resultant jet Jr are distributed angularly in a uniform manner and these axes being inclined relative to the said axis (A) by the same non-zero angle α of not more than 90°;   b) simultaneously directing at the point of impingement (I) at least one jet Jb of a fluid which is different from at least one of the fluids of the said jets Ja for forming the resultant jet Jr, the axis of the jet(s) Jb being inclined relative to the axis of the resultant jet Jr by an angle β which is less than the angle α; and   c) recovering the mixture of the fluids in the jets Ja and Jb in the form of the resultant jet Jr consisting of the homopolymers or copolymers.

This Application is a Division of U.S. application Ser. No. 09/911,708 filed Jul. 25, 2001, now U.S. Pat. No. 6,590,052 and is a Continuation of U.S. patent application Ser. No. 09/181,079 filed Oct. 27, 1998, now abandoned.

DESCRIPTION

The present invention relates to a process and a device for the continuous micromixing of fluids, leading to the polymerization of monomer(s) and to the obtainment of homopolymers or copolymers.

Good continuous micromixing of fluids is desired in the case of certain very rapid reactions, as well as in the case where it is desired to rapidly homogenize two or more miscible or immiscible fluids.

The process and the device according to the invention can be used in particular when the micromixing plays an important role, for example, in the yield and characteristics of the products. This is the case, in particular, for crystallization, precipitation and combustion reactions and for polymerization and copolymerization reactions.

The invention is particularly useful for ultra-fast (co)polymerizations leading to (co)polymers of controlled mass and polydispersity and, preferably, with a high solids content; this is the case, in particular, for the anionic polymerization of (meth)acrylic monomers.

The mixing of two or more fluids in a very short space of time may be necessary in certain circumstances and in particular when these fluids are reactive with each other and when the chemical reaction kinetics are complex and/or rapid. It is thus convenient, in certain cases, to mix the reactants at the molecular level (micromixing) in a time shorter than the characteristic reaction time.

To characterize the micromixing, parallel-concurrent or consecutive-concurrent type reactions can be used as test reactions.

This is the case, for example, for parallel-concurrent reactions of the type:

A+B→R (1)

C+B→S (2)

or consecutive-concurrent reactions of the type:

A+B→R (1′)

B+R→S (2′)

in which A, B and C are reactants and R and S are products.

In the parallel-concurrent reaction system, B is mixed, in stoichiometric deficit, with a mixture containing A and C. In the consecutive-concurrent reaction system, B is mixed, in stoichiometric deficit, with A. In general, R is the desired product and S is a side product. In both cases, the reaction rates (1) and (1′) are greater than those for the reactions (2) and (2′) respectively.

The proportion of R and S depends on the quality of the micromixing between A and B:

-   -   if the micromixing is good, i.e. if the characteristic         micromixing time is less than the characteristic time for the         reaction (2) or (2′), depending on the case, essentially only R         will be formed;     -   on the contrary, if the micromixing is poor, i.e. if the         characteristic micromixing time is greater than the         characteristic time for the reaction (2) or (2′), depending on         the case, S will also be formed. The amount of S formed thus         depends both on the micromixing (the poorer the micromixing, the         more S will be formed) and on the stoichiometry of the         reactions.

In general, if S is an undesirable side product, it will be advantageous to promote good micromixing in order to increase the yield of R and, in this way, to reduce the costs of separation between R and S and to avoid the formation of a side product S which cannot be viably upgraded.

In the case of living polymerization reactions, i.e. a polymerization, in particular one which is free or virtually free of termination and/or transfer reactions, micromixing makes it possible to control the molar mass distribution. The reason for this is that one of the particular features of this type of polymerization lies in the fact that it is possible to obtain very narrow molar mass distributions, i.e. all of the macromolecular chains contain virtually the same number of monomer units. However, this condition is satisfied only if, on the one hand, the initiation reaction takes place rapidly before the propagation reactions have begun, and, on the other hand, the chains grow simultaneously. Initiation systems allow the first condition of rapid initiation to be satisfied. On the other hand, only good micromixing between the initiator and the monomer will allow the simultaneous growth of the macromolecular chains. If the micromixing is not good, some chains will start to grow before others, which, in the end, will result in broadening of the molar mass distribution.

Currently, one of the techniques most commonly used for mixing two or more liquids consists in using a closed, semi-closed or open tank, fitted with a mechanical stirrer such as a propeller or turbomixer or the like, and in injecting one or more of the reactants into the tank.

The mixing can be carried out by virtue of the energy dissipated by the mechanical stirring. Unfortunately, these devices do not make it possible, in certain cases, to achieve micromixing times that are short enough to carry out rapid and complex reactions, and above all, they are unsuitable in the case of polymerization reactions in which the viscosity increases rapidly over time.

Static mixers, placed in line in a conduit or at a reactor inlet, allow good mixing of liquids. However, they are usually used as premixers before the reactor inlet or when the time constraints are not prohibitive. They are good devices for homogenizing solutions, but are not really suitable for certain polymerization reactions, in particular rapid reactions, since there are considerable risks of blockage. This is the case, in particular, for polymerizations at a high solids content.

Tangential-jet mixers (which can be used in particular for anionic polymerization as described in EP-A-0,749,987) or RIM (reaction injection moulding) heads are confined-jet mixers, i.e. mixers involving jets which are in contact with the wall of the mixer. They are highly effective, but result in blockages when high polymer contents are used or require the injection of products by pumps which can withstand high pressures (several hundred bar). Furthermore, RIM heads require a batchwise operation.

Free-impinging-jet mixing (i.e. mixing without jets coming into contact with the walls of the mixer) is known, and has been described for creating emulsions or in liquid-liquid extraction processes, for example by Abraham Tamir, “Impinging-Stream-Reactors. Fundamentals and Applications”, Chap. 12: Liquid-Liquid Processes, Elsevier (1994).

Free-impinging-jet devices have also been described for precipitation or polymerization. They consist of two jets oriented at a given angle and whose impingement results in a rapid micromixing; cf. Amarjit J. Mahajan and Donald J. Kirwan “Micromixing Effects in a Two Impinging-Jets Precipitator, Aiche Journal, Vol. 42, No. 7, pages 1801-1814 (July 1996); Tadashi Yamaguchi, Masayuki Nozawa, Narito Ishiga and Akihiko Egastira “A Novel Polymerization Process by Means of Impinging Jets”, Die Angewandte Makromolekulare Chemie 85 (1980) 197-199 (No. 1311). The drawback of these systems is that they only allow two fluids to be mixed and that the jets are all of the same diameter and, consequently, if it is desired for the mixing to be efficient, the respective flow rates in each jet must all be equal to each other. In the case of a polymerization reaction, since the monomer arrives in a first jet and the initiator solution arrives in a second jet at the same flow rate as the first, it is thus seen that the amount of solvent in the system will necessarily be relatively large, which means having to involve recycling operations, that are generally expensive, downstream of the polymerization process.

The subject of the present invention is thus a polymerization process comprising continuous free-impinging-jet micromixing, which no longer incurs the limitations which have just been described, as well as a device for carrying out this process.

The process according to the invention, for the continuous preparation of homopolymers or copolymers by free-impinging-jet micromixing of fluids formed (1) of monomer(s) and (2) of an initiator system, is characterized in that the said fluids (1) and (2) are micromixed and the mixture of these fluids is recovered in the form of a resultant jet Jr, originating from the point of impingement (I), the micromixing being obtained by:

a) forming at least one group of at least two jets Ja of the said identical or different fluids, these jets coinciding at a point of impingement (I), the jets Ja of the same group all being of identical geometry, their axes being arranged such that their projections on a plane perpendicular to the axis (A) of the resultant jet Jr are distributed angularly in a uniform manner and these axes being inclined relative to the said axis (A) by the same non-zero angle α of not more than 90°;

b) simultaneously directing at the point of impingement (I) at least one jet Jb of a fluid which is different from at least one of the fluids of the said jets Ja for forming the resultant jet Jr, the axis of the jet(s) Jb being inclined relative to the axis of the resultant jet Jr by an angle β which is less than the angle α; and

c) recovering the mixture of the fluids in the jets Ja and Jb in the form of the resultant jet Jr consisting of the homopolymers or copolymers.

The jets Ja and Jb are preferably arranged such that the resultant jet Jr, obtained from the point of impingement (I), has a vertical direction directed downwards.

The term “geometry” is understood to refer to the shape of the jets Ja and Jb, which can be in cylindrical, conical, sheet, etc. shape. Preferably, the jets are cylindrical and have a cross-sectional diameter of, for example, between 0.01 mm and 100 mm, and preferably between 0.1 mm and 10 mm. The jets Ja and Jb can have the same geometrical shape.

The term point of impingement is understood to refer to the initial zone of contact between all of the jets.

The angle α is preferably from 10 to 60°; the angle β is from 0 to 89°. The angle β is preferably 0°. The direction of the single jet Jb then joins together with that of the resultant jet Jr.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view showing two jets of fluid impinging to form a resultant jet of fluid;

FIG. 2 is a schematic view showing two groups of fluid jets impinging to form a resultant jet;

FIG. 3 is a schematic view showing two groups of fluid jets impinging to form a resultant jet with the resultant jet forming an axis of symmetry;

FIG. 4 is a schematic view showing two groups of impinging fluid jets, one being downstream of the other;

FIG. 5 is an axial cross-section of a micromixer in accordance with a first embodiment of the invention;

FIG. 6 is a top view along the arrow F of FIG. 5;

FIG. 7 is an axial cross-section of a micromixer in accordance with a second embodiment of the invention according to the scheme in FIG. 4;

According to one embodiment, represented diagrammatically in FIG. 1, a group of two jets Ja and a jet Jb are formed, these jets coinciding at a point of impingement (I) to form the resultant jet Jr. The axis of the jet Jb corresponds to the axis (A) of the resultant jet Jr which serves as the axis of symmetry for the jets Ja. Needless to say, the group can comprise more than two jets Ja.

According to another embodiment, represented diagrammatically in FIG. 2, a first group of jets Ja₁, a second group of jets Ja₂ and a jet Jb are formed, all the jets coinciding at a point of impingement (I) to form a resultant jet Jr which acts as the axis of symmetry for the jets Ja₁ and Ja₂ which form, with this axis, angles α1 and α2 respectively.

According to one embodiment, a group of at least two jets Jb of identical or different fluids is directed at the point of impingement (I), the jets Jb all being of identical geometry, their axes being arranged such that their projections on a plane perpendicular to the axis (A) of the resultant jet Jr are distributed angularly in a uniform manner and these axes being inclined relative to the said axis (A) by the same angle β.

Such an embodiment is represented diagrammatically in FIG. 3, in which a group of two jets Ja and a group of two jets Jb are formed, these jets coinciding at a point of impingement (I) to form the resultant jet Jr, the latter jet serving as the axis of symmetry for the jets Ja and Jb. Needless to say, each group can comprise more than two jets.

According to another embodiment, the jet Jr can be used as one of the jets Ja or Jb in order to prepare another micromixture in a step downstream; advantageously, the jet Jr is used as jet Jb in the micromixing downstream, as represented diagrammatically, for example, in FIG. 4.

In all cases, the jets from the same group all have the same geometry and consist of identical or different fluids provided that at least one of the jets Jb is formed of a fluid which is different from one of the fluids in the jets Ja.

In the same group of jets, Ja or Jb, the flow rates of these jets are identical.

The flow rates of the jets Ja and Jb can be identical.

A preferred embodiment is one in which the jet(s) Jb has (have) a different flow rate from that of at least one group of jets Ja.

The flow rate of the fluids in each of the jets Ja and Jb is, for example, from 1 g/h to 10,000 kg/h, in particular from 1 kg/h to 1000 kg/h.

The micromixing process according to the invention can allow reactions other than the polymerization or copolymerization reaction, for example a crystallization, precipitation or combustion reaction.

The fluids are generally liquids. The fluids can be fluids capable of reacting together or can contain components capable of reacting together. If the reaction is rapid, it starts virtually at the point of impingement (I).

The process according to the present invention is advantageously carried out in a chamber equipped for recovery of the resultant jet Jr, it being possible for the said chamber to be temperature and pressure-adjusted. Thus, the pressure prevailing in the chamber can be from 1 mbar to 3000 bar, in particular from 0.1 to 100 bar, and the temperature can be from −100° C. to 1500° C., in particular from −80° C to +200° C.

The (co)polymerization resulting from the micromixing of fluids formed of monomer(s) and of an initiator system leads to the formation of homopolymers, random copolymers and block copolymers.

The monomers can be pure or in polar or non-polar solvent medium.

The jets Ja are advantageously jets of monomers which are pure or in solvent medium, and the jet(s) Jb is (are) advantageously jets of initiator system.

In particular, in the case of preparing homopolymers, the jets Ja (for example according to the schemes in FIGS. 1 and 3) consist of monomers, and the jet(s) Jb consist(s) of the initiator system. The polymer is recovered in the resultant jet Jr.

In the case of a random copolymerization (carried out, for example, according to the scheme in FIG. 2), the jets Ja1 are formed of monomer M₁ and the jets Ja2 are formed of monomers M₂ and the copolymer is recovered in the jet Jr.

Optionally, in order to obtain a random copolymer, a process represented diagrammatically in FIG. 1 or 3 can also be used, in which a jet Ja can comprise a mixture of monomers M₁ and M₂ or alternatively one of the jets Ja consists of the monomer M₁ and the other jet Ja consists of the monomer M₂.

In order to prepare block copolymers, a process represented diagrammatically, for example, in FIG. 4 can be used, in which the jets Ja are formed of monomer M and the jet Jb is formed of initiator system. The resultant jet Jr is formed by the living polymer and serves as initiator for the polymerization of the monomer M′ in the jets Ja′, this polymerization following the micromixing at the point of impingement (I′) of the jets Jr and of the jets Ja′; the block copolymer is recovered in the resultant jet Jr′.

In order to obtain block copolymers, a process represented diagrammatically in FIGS. 1 to 3 can also be used, in which the jet(s) Jb consist(s) of an initiator in the form of living polymer.

It is also possible for a jet Ja to consist of monomer(s) and for another jet Ja to be formed of the initiator system of the moment, as indicated above, and for all the jets of this group to have the same geometry. In this case, the jet Jb can consist of monomer(s).

The advantage of the process of the invention is that these polymers can be obtained without blocking the reactor, optionally with a high solids content and a reduced amount of solvent.

The monomers which can be (co)polymerized are, in particular, those mentioned in the document EP-A-749,987. They are acrylic, methacrylic, vinyl aromatic, diene and maleimide monomers.

The methacrylic and acrylic monomers are, for example, those which correspond to the following formulae:

in which R is chosen from C₁ C₁₈ alkyl radicals which are linear or branched, and primary, secondary or tertiary, C₅-C₁₈ cycloalkyl radicals, C₁-C₁₈ (C₁-C₁₈ alkoxy)alkyl radicals, C₁-C₁₈ (C₁-C₁₈ alkylthio)alkyl radicals, aryl and arylalkyl radicals, these radicals being optionally substituted with at least one halogen atom and/or at least one hydroxyl group after protection of this hydroxyl group, the above alkyl groups being linear or branched; glycidyl, norbornyl and isobornyl (meth)acrylates and mono- and di(C₁-C₁₈ alkyl)-(meth)acrylamides.

Examples of useful methacrylates which may be mentioned are methyl, ethyl, 2,2,2-trifluoroethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, n-amyl, isoamyl, n-hexyl, 2-ethylhexyl, cyclohexyl, octyl, isooctyl, nonyl, decyl, lauryl, stearyl, phenyl, benzyl, β-hydroxyethyl, isobornyl, hydroxypropyl and hydroxybutyl methacrylates. The preferred methacrylic monomer is methyl methacrylate.

Examples of acrylates of the above formula which may be mentioned are methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, hexyl, 2-ethylhexyl, isooctyl, 3,3,5-trimethylhexyl, nonyl, isodecyl, lauryl, octadecyl, cyclohexyl, phenyl, methoxymethyl, methoxyethyl, ethoxymethyl and ethoxyethyl acrylates.

The term “maleimide”, as employed above,-denotes an unsubstituted maleimide monomer or an N-substituted maleimide monomer of formula:

in which R′ is an alkyl, arylalkyl, aryl or alkylaryl radical having from 1 to 12 carbon atoms. Non-limiting examples are: N-ethylmaleimide, N-isopropylmaleimide, N-n-butylmaleimide, N-isobutylmaleimide, N-tert-butylmaleimide, N-n-octylmaleimide, N-cyclohexylmaleimide, N-benzyl-maleimide and N-phenylmaleimide. The preferred maleimide is N-cyclohexylmaleimide.

The term vinylaromatic monomers refers to an aromatic monomer containing ethylenic unsaturation, such as styrene, vinyltoluene, alpha-methylstyrene, 4-methylstyrene, 3-methylstyrene, 4-methoxystyrene, 4-ethylstyrene, 3,4-dimethylstyrene, 3-tert-butylstyrene, 2,4-dichlorostyrene, 2,6-dichlorostyrene, 1-vinylnaphthalene, 2-vinylpyridine and 4-vinylpyridine.

The term diene monomer refers to a diene chosen from linear or cyclic, conjugated or non-conjugated dienes such as, for example, butadiene, isoprene and 1,3-pentadiene.

One particularly advantageous embodiment is anionic polymerization or copolymerization in which one of the monomers is an acrylic or methacrylic monomer such as methyl methacrylate.

The initiator system can be a solution of at least one initiator or a solution of at least one initiator and of at least one additive such as a ligand. In the case of block copolymerization, the initiator can be a living polymer or copolymer, in solvent medium where appropriate, optionally combined with an additive such as a ligand.

As initiator, it is possible to use a monofunctional initiator of general formula (I): R¹—M in which:

-   -   M denotes an alkali metal or alkaline-earth metal; and     -   R¹ denotes:     -   an alkyl radical with a straight or branched chain, containing 2         to 6 carbon atoms; or     -   an aryl radical with one or more rings, optionally substituted;         or     -   a C₂-C₆ alkenyl radical substituted with aryl or alkylaryl; or     -   a linear or branched alkyl radical containing 1 to 6 carbon         atoms, substituted with at least one phenyl group,         or an anionic monofunctional initiator for (meth)acrylates         chosen from α-lithioisobutyrates and amides,

or alternatively a difunctional initiator of formula (II):

in which:

-   -   M is as defined above; and     -   R² represents an aliphatic, cycloaliphatic or aromatic divalent         organic radical or an organic radical containing at least one         cycloaliphatic or aromatic group, it being possible for R² to         contain substituents, and     -   R³ and R⁴ each independently represent an aliphatic,         cycloaliphatic or aromatic monovalent organic radical or an         organic radical containing at least one cycloaliphatic or         aromatic group, it being possible for R³ and R⁴ to contain         substituents.

Examples of monofunctional initiators of formula (I) which may be mentioned are sec-butyllithium, n-butyllithium, fluorenyllithium, alpha-methylstyryllithium, 1,1-diphenylhexyllithium (DPHLi), diphenylmethyllithium or -sodium or -potassium and 1,1-diphenyl-3-methylpentyllithium.

Examples of difunctional initiators of formula (II) which may be mentioned are 1,1,4,4-tetra-phenyl-1,4-dilithiobutane and 1,1,4,4-tetraphenyl-1,4-disodiobutane.

It is also possible to use well-known difunctional initiator precursors, such as naphthalene-lithium, naphthalenesodium, naphthalenepotassium and homologues thereof.

Moreover, the initiator as defined above is combined with at least one ligand consisting of an alkali metal alkoxide of formula (III) or (IV): R⁵(OR⁶)_(n)OM¹  (III) M¹(OR⁶)_(n)OM¹  (IV) in which:

-   -   M¹ represents an alkali metal;     -   R⁵ is a linear or branched alkyl radical having from 1 to 6         carbon atoms or an arylalkyl radical in which the alkyl residue         is C₁-C₆, or an alkylaryl radical in which the alkyl group has         from 1 to 6 carbon atoms;     -   R⁶ is a linear or branched alkylene radical having from 2 to 4         carbon atoms;     -   n is the integer 1, 2 or 3.

Examples of such alkoxides which may be mentioned are those in which the radical R⁵ is a methyl, ethyl, butyl or benzyl radical, R⁵ advantageously being the methyl radical, and R⁶ is the ethylene, propylene, butylene or isopropylene radical, R⁶ preferably being the ethylene radical. M¹ is lithium, sodium or potassium and preferably represents lithium.

Specific examples are as follows:

-   -   CH₃(OCH₂CH₂)OLi     -   CH₃(OCH₂CH₂)₂OLi     -   CH₃(OCH₂CH₂)₃OLi     -   nBu(OCH₂CH₂)₂OLi     -   Et(OCH₂CH₂)₂OLi     -   Li(OCH₂CH₂)₂OLi     -   Li(OCH₂CH₂)₃OLi

The alkoxides of formulae (III) and (IV) are prepared, for example, by reaction of R⁵(OR⁶)_(n)OH or H(OR⁶)_(n)OH respectively with any base whose pKa is higher than the pKa of the R⁵(OR⁶)_(n)OM¹/R⁵(R⁶)_(n)OH couple or of the M¹(OR⁶)_(n)OM¹/H(OR⁶)_(n)OH couple. Thus, the lithium alkoxides may be prepared by reaction with lithium metal or by reaction with an organometallic lithium compound in a polar or apolar solvent.

The initiating system can also comprise an alcoholate ligand such as those described here above and a monofonctional or a difunctional silylated initiator such as:

-   -   a) a monofunctional initiator having the formula:         wherein:     -   R¹, R², R³ each independently represent a linear or branched         alkyl radical, containing 1 to 8 carbon atoms;     -   R⁴ represents a linear or branched alkylene radical containing 1         to 8 carbon atoms;     -   M designates an alkaline metal or alkaline earth metal (valence         q is 1 or 2),

b) a difunctional initiator having the formula:

wherein:

-   -   R⁵ and R⁶ each independently represent a linear or branched         alkyl radical containing 1 to 8 carbon atoms;     -   R⁷ and R⁸ each independently represent a linear or branched         alkylene radical containing 1 to 8 carbon atoms; and     -   M′ designates an alkaline metal.

In the formulae above, R1, R2, R3, R5 and R6 each preferably represent an alkyl radical with, preferably, 1 to 4 carbon atoms and very particularly, a methyl radical; R4, R7 and R8 each preferably represent an alkylene radical with 1 or 2 carbon atoms and particularly the methylene radical, and M and M′ each preferably represent lithium. A particularly appropriate initiator is trimethylsilylmethyl-lithium.

The molar ratio of the ligand of formula (III) or (IV) to the initiator in the initiator system as defined above may vary within a very wide range. The amount of ligand (III) or (IV) must be sufficient to allow the formation of a complex with the polymerization active centre and thus to stabilize the latter. The amount of ligand (III) or (IV) depends on the initiator chosen and on the monomers to be (co)polymerized. The ligand (III) or (IV)/initiator molar ratio is generally between 1 and 50. In order to obtain the best results, this ratio is preferably between 1 and 10.

The monomer(s) may be in solution in at least one polar or non-polar solvent chosen from aromatic solvents such as benzene, toluene and ethylbenzene and solvents such as tetrahydrofuran, diglyme, tetraglyme, ortho-terphenyl, biphenyl, decalin, tetralin or dimethylformamide. The initiator and the ligand are in solution in a solvent of the same type.

The monomers are used, for example, pure or dissolved at a concentration of 10 to 90% monomer; the monomers are preferably used pure.

The (co)polymers formed by anionic polymerization in the resultant jet Jr are living, i.e. they can initiate a new polymerization if an amount of monomer is added. In order to obtain (co)polymers from these living (co)polymers, these living polymers can be deactivated by reaction with a source of protons (for example alcohol, water, protic acid).

In order to carry out the micromixing according to the invention, leading in particular to a (co)polymer via an anionic route, the ratio between the overall flow rate by weight of the jets Ja consisting of the monomers and the overall flow rate of the jet Jb or the overall flow rate by weight of the jets Jb (comprising the initiator system) can be from 0.01 to 100, preferably from 1 to 20. This ratio is preferably constant.

The angle of impingement between the axis of the jets of monomers and the axis of the resultant jet Jr is less than 90°, preferably between 10 and 60° and most particularly between 30 and 45°.

The duration of the micromixing is as short as possible and is less than the (co)polymerization time in order to avoid a non-simultaneous propagation of the chains, which would lead to poor control of the polymerization. The duration is generally at least 0.001 s, in particular from 0.005 to 10 s.

The temperature, at the point of impingement (I) is from about −100° C. to +200° C. and preferably from −80° C. to +100° C.

The polymerization preferably takes place under adiabatic conditions.

The present invention also relates to a device for carrying out the polymerization process defined above.

The device according to the invention is used for the continuous free-impinging-jet micromixing of at least two monomer fluids and an initiator system and in recovering the polymer mixture in the form of a resultant jet Jr. It comprises:

a) means for forming at least one group of at least two jets Ja of identical or different fluids, these jets coinciding at a point of impingement (I), the jets of the same group all being of identical geometry, their axes being arranged such that their projections on a plane perpendicular to the axis (A) of the resultant jet Jr are distributed angularly in a uniform manner and these axes being inclined relative to the said axis (A) by the same non-zero angle α of not more than 90°;

b) means for directing at the point of impingement (I) at least one jet Jb of a fluid which is different from at least one of the fluids of the said jets Ja for forming a resultant jet Jr, the axis of the jet(s) Jb being inclined relative to the axis (A) by an angle β which is less than the angle α, and

c) means for recovering the mixture of the fluids in the jets Ja and Jb in the form of the resultant jet Jr.

In particular, the device comprises, as means for forming the jets Ja and Jb, nozzles equal in number to the number of jets Ja and Jb, these nozzles being fixed to a nozzle holder and connected, at the inlet, to fluid inlet tubes and being arranged and oriented to allow, at their outlet, the formation of free jets Ja and Jb and their point of impingement (I), and, as means for recovering the mixture, a chamber connected to the nozzle holder. Means are provided to ensure the necessary flow rates of the jets Ja and Jb.

The nozzles are advantageously removable to allow them to be exchanged with nozzles of different geometry. Thus, the nozzles can consist of tubes of variable diameter or whose outlet end is of variable inside diameter, or onto which distribution heads of variable outlet diameter can be fitted.

For polymerization, the device is intended for the micromixing of fluids which are capable of reacting together, and the chamber forms with the nozzle holder a reactor containing means for adjusting the temperature and pressure. The chamber is advantageously cylindrical with a base which is conical, for example, allowing recovery of the jet Jr.

When the jet Jr is used as a jet Jb in a new micromixing operation downstream, this nozzle holder and this chamber are advantageously designed to form a first module, a second nozzle holder being provided on the outlet of the said chamber (the said second nozzle holder containing, instead of the nozzle normally associated with the said jet Jb, an orifice allowing passage of the jet Jr) and a second chamber being connected to the said second nozzle holder to form a second module, it being possible for other modules of the same type to be provided, where appropriate.

It goes without saying that the device of the invention and its constituent elements are made of materials which are compatible with the fluids conveyed.

Two embodiments of a device according to the present invention will now be described, for non-limiting illustration purposes, with reference to the attached figures:

FIG. 5 is an axial cross-section of a micromixer in accordance with a first embodiment of the invention;

FIG. 6 is a top view, along the arrow F of FIG. 5; and

FIG. 7 is an axial cross-section of a micromixer in accordance with a second embodiment of the invention (according to the scheme in FIG. 4).

The micromixer represented in FIGS. 5 and 6 comprises a nozzle-holder element (1) which contains a cylindrical wall (2) connected to a cylindrical wall (3), of smaller thickness and smaller diameter, by a frustoconical shoulder (4), the cylindrical wall (3) being, at its end opposite to the shoulder (4), closed by a circular base (5). At its free end opposite to this circular base, the cylindrical wall (2) is folded outwards at a right-angle to form a flange (6).

Four cylindrical orifices (7) are made in the frustoconical shoulder (4), these holes being uniformly spaced and oriented such that their axes intersect at a point located on the axis of the nozzle holder (1), on the inside. In the example represented, the axis of an orifice (7) forms an angle of 30° with the axis of the nozzle holder (1).

A tube (8) is inserted and held, by force-fitting, in each orifice (7) and along the axis thereof, this tube, once mounted, projecting both externally and internally. The external parts serve to connect fluid inlet tubes and the internal parts have, for example, an external thread to receive a distribution head (9).

Each distribution head (9), consisting of a side distribution nozzle with the associated tube (8), contains a cylindrical wall (9 a) fitted on the inside with means for fixing to the tube (8), for example a screw thread intended to match up with the thread on the tube (8), the cylindrical wall (9 a) being connected to a base (9 b) containing an axial fluid outlet orifice (9 c). By providing a set of distribution heads (9) with different orifice diameters (9 c), the diameter of the jets of fluid Ja leaving the four side distribution nozzles can be varied.

The circular base (5) contains, at its centre, a cylindrical orifice (10) into which is force-fitted a tube (11) which has, close to one of its ends, a flange (12) which, in the mounting position, bears against the external wall of the base (5). This flange (12) contains four uniformly distributed orifices (12 a) which accept screws (13) for fixing the tube (11) to the nozzle holder (1). The base (5) also includes a circular groove (14), centred on the axis of the orifice (10), in the internal space of the holes for accepting the screws (13), this groove (14) receiving a seal (not represented).

In the same way as for the tubes (8), the tube (11), once mounted on the nozzle holder (1) contains an external part, which projects beyond the flange (12), for connecting a fluid inlet tube, and an internal part which projects beyond the base (5) and whose internal wall is of smaller diameter (11 a) in its end part. This thus makes an axial distribution nozzle for a jet Jb of fluid, which, in operating mode, will encounter the side jets Ja at the point of impingement (I) to continue as a resultant axial jet Jr.

By providing a set of tubes (11) with different outlet diameters (11 a), the diameter of the jet of fluid Jb can be varied. Moreover, it goes without saying that it may, according to a variant, be envisaged to fit onto the internal mouth of the tube (11) a distribution head similar to the distribution heads (9) associated with the side tubes (8). In the same way, to vary the outlet diameter of the side nozzles, sets of tubes (8) having different diameters at the outlet end may be provided.

The flange (6) of the nozzle holder (1) contains four uniformly distributed openings (15) for accepting the screws (16) which fix the nozzle holder (1) onto the upper flange (17 a) of a chamber (17) of tubular-general shape, of the same axis as the nozzle-holder element (1).

The resultant axial jet Jr, which flows along the axis of this chamber, is the site of the reaction between the fluids perfectly mixed at the point of impingement (I). The reaction product is then recovered in the base of the chamber (17), which can contain pressurization means and heating or cooling means, as well as means for adjusting the temperature and pressure prevailing in the chamber, depending on the reaction considered.

FIG. 7 is a diagram of an apparatus in accordance with a second embodiment of the present invention, which is more or less identical to that described with reference to FIGS. 5 and 6 (in which the constituent elements, which will not be described again, are denoted by the same reference numbers), the chamber (17) cooperating, at its lower part, with a second nozzle holder (101).

The nozzle (101) is identical to the nozzle holder (1), except that its base (105) does not have a tube (111) and extends laterally as a peripheral circular base plate (105 a), which bears a lower flange (17 b) of the chamber (17), in order to fix together the nozzle holder (1) and the nozzle holder (101) by means of screws; (the constituent elements of the nozzle holder (101) are denoted with the same reference numbers as those of the nozzle holder (1), to which 100 has been added).

In this case, in operating mode, the jet Jr passes through the orifice (110) made in the base (105) to mix, at the point of impingement (I′) in the chamber (117), with side jets Ja′ of a fluid intended to be combined or to react with the product in the jet Jr, the side jets Ja′ being formed in the same way as the side jets Ja. The resultant jet Jr′ may itself constitute a new axial jet for mixing with new side jets.

The examples which follow illustrate the present invention without, however, limiting the scope thereof. The methyl methacrylate (MMA) used in these examples is purified by standing over molecular sieves and then over alumina; the toluene and the tetrahydrofuran (THF) are purified over molecular sieves.

EXAMPLE 1

Continuous Anionic Polymerization of MMA Using a Free-Impinging-Jet Micromixer.

20 kg of pure MMA are introduced into a 30 l storage tank C1 maintained under inert atmosphere at −21° C.

An initiator solution is prepared in a 30 l storage tank C2 maintained under inert atmosphere at −23° C., by first introducing the purified solvent, i.e. 17.50 kg of a mixture of toluene and tetrahydrofuran in an 88:12 mass ratio, and then adding:

-   -   304.40 g (315.40 ml) of 2-methoxyethanol,     -   2 ml of 1,1-diphenylethylene (DPE) (coloured indicator), and     -   2.5 l of a 1.6 M solution of butyllithium in hexane         in order to prepare the ligand CH₃—O—CH₂CH₂-OLi by reaction of 4         mol of CH₃—O—CH₂CH₂—OH with 4 mol of BuLi in the presence of the         DPE coloured indicator; and then adding:     -   173.04 g (169.48 ml) of DPE, and     -   0.5 l of a 1.6 M solution of BuLi in hexane,         in order to prepare the initiator, whose concentration, in the         storage tank C2, is 3.39×10⁻² mol/l.

The MMA and the initiator solution contained in the storage tanks C1 and C2 respectively are pumped and passed first through an exchanger which produces a mixture temperature of −25° C., and then into a micromixer of the type described in FIGS. 5 and 6, in which the monomer is introduced at a total flow rate of 81 kg/h as the four side jets Ja (i.e. 20.25 kg/h in each jet); the jets Ja are each inclined at an angle of 45° relative to the vertical and emerge from the distribution head (9) whose diameter is 2 mm; the initiator solution is introduced at a flow rate of 18 kg/h as the vertical axial jet Jb emerging from the distribution head (11), the diameter of which is 1.5 mm.

The distance travelled by the jets Ja between the distribution head outlet (9) and the point of impingement (I) is 30 mm, and the distance travelled by the jet Jb between the tube outlet (11) and the point of impingement (I) is 40 mm.

The tubular chamber (17) associated with the nozzle-holder element (1) forms the polymerization reactor in which the pressure is maintained at 1 bar absolute of nitrogen, and the temperature is maintained at 20° C.

At the point of impingement (I), the MMA concentration is 7.38 mol/l and the initiator concentration is 7.38×10⁻³ mol/l. The duration of the micromixing is about 5 ms. Polymerization of the MMA takes place in the resultant jet Jr which travels a distance of 500 mm to the conical base of the chamber (17), where the solution of PMMA, which contains 41% by weight of solids, is recovered.

The PMMA has an {overscore (M)}n of 65,600 g/mol.

EXAMPLE 2

Continuous Anionic Polymerization of MMA Using a Free-Impinging-Jet Micromixer.

20 kg of pure MMA are introduced into a 30 l storage tank C1 maintained under inert atmosphere at −24° C.

An initiator solution is prepared in a 30 l storage tank C2 maintained under inert atmosphere at −34° C., by first introducing the purified solvent, i.e. 7.90 kg of a mixture of toluene and tetrahydrofuran in an 88:12 mass ratio, and then adding:

-   -   253.67 g (262.87 ml) of 2-methoxyethanol,     -   2 ml of 1,1-diphenylethylene (DPE) (coloured indicator), and     -   2.083 l of a 1.6 M solution of BuLi in hexane         in order to prepare the ligand CH₃—O—CH₂CH₂-OLi as in Example 1;         and then adding:     -   144.20 g (141.23 ml) of DPE, and     -   0.42 l of a 1.6 M solution of BuLi in hexane,         in order to prepare the initiator, whose concentration, in the         storage tank C2, is 5.55×10⁻² mol/l.

The MMA and the initiator solution contained in the storage tanks C1 and C2 respectively are pumped and passed first through an exchanger which produces a mixture temperature of −26° C., and then into a micromixer of the type described in FIGS. 5 and 6, in which the monomer is introduced at a total flow rate of 80 kg/h as the four side jets Ja (i.e. 20 kg/h in each jet); the jets Ja are each inclined at an angle of 30° relative to the vertical and emerge from the distribution head (9) whose diameter is 2 mm; the initiator solution is introduced at a flow rate of 20 kg/h as the vertical axial jet Jb emerging from the distribution head (11), the diameter of which is 1 mm.

The distance travelled by the jets Ja between the distribution head outlet (9) and the point of impingement (I) is 30 mm, and the distance travelled by the jet Jb between the tube outlet (11) and the point of impingement (I) is 40 mm.

The tubular chamber (17) associated with the nozzle-holder element (1) forms the polymerization reactor in which the pressure is maintained at 3.5 bar absolute of nitrogen, and the temperature is maintained at 20° C.

At the point of impingement (I), the MMA concentration is 7.35 mol/l and the initiator concentration is 1.22×10⁻² mol/l. The duration of the micromixing is about 5 ms. Polymerization of the MMA takes place in the resultant jet Jr which travels a distance of about 500 mm to the conical base of the chamber (17), where the solution of PMMA, which contains 51% by weight of solids, is recovered.

The PMMA has an {overscore (M)}n of 32,600 g/mol.

EXAMPLE 3

Continuous Synthesis of a Polybutadiene-PMMA Block Copolymer.

The example shows that a block copolymer can be prepared with the device according to the invention.

The process is generally performed as in Examples 1 and 2, except that the initiator solution consists of a solution of living polybutadiene and that a micromixing and reaction device is used which is capable of producing:

-   -   four side jets Ja of pure MMA emerging from distribution         heads (9) 2 mm in diameter, the jets Ja each being inclined at         an angle of 45° relative to the vertical, and     -   a vertical axial jet Jb of initiator solution (living         polybutadiene) emerging from a distribution head (11) 1.5 mm in         diameter.

A batch reactor under inert atmosphere is used to prepare the initiator solution; 12.8 kg of purified toluene are introduced therein and heated to 50° C., followed by addition of 30.2 g of BuLi (1.3 M in hexane) as initiator. Next, 3.2 kg of butadiene are added while monitoring the exothermicity and the variation in pressure; the mixture is cooled to −15° C., followed by addition of a solution of DPE and of alkoxide CH₃—O—CH₂CH₂-OLi obtained by reacting 27.1 g of 2-methoxyethanol with 222.2 ml of BuLi (1.6 M in hexane) and 25.6 g of DPE and 2.8 kg of toluene. An initiator solution is thus obtained containing living polybutadiene of {overscore (M)}n=41,100 g/mol, which is stored at −20° C. in a 40 l storage tank C2.

A storage tank C1 contains a solution of 21 kg of MMA in 35.9 kg of toluene at −29° C.

A copolymer composition of 60% polybutadiene/40% PMMA by weight is targeted. The solids content envisaged for the copolymer is 9.4%.

The MMA solution and the initiator solution (living polybutadiene) contained in the storage tanks C1 and C2 respectively are pumped and the flows are then injected into the micromixing device whose characteristics were mentioned above, the total flow rate of the MMA solution being 80 kg/h (i.e. 20 kg/h in each jet) and the flow rate of the initiator solution being 32.5 kg/h.

The distance travelled by the jets Ja between the distribution head (9) outlet and the point of impingement (I) is 30 mm and the distance travelled by the jet Jb between the tube outlet (11) and the point of impingement (I) is 40 mm.

The tubular chamber (17) associated with the nozzle-holder element (1) forms the copolymerization reactor in which the pressure is maintained at 1 bar absolute of nitrogen and the temperature is maintained at 20° C.

The copolymerization takes place in the resultant jet Jr which travels a distance of about 500 mm to the base of the chamber (17), where the solution of polybutadiene-PMMA block copolymer, which contains 8.7% by weight of solids, is recovered.

The polybutadiene-PMMA copolymer has an Mn of 68,700 g/mol. The polybutadiene and PMMA contents, determined by proton NMR, are, respectively, 60% and 40%.

The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.

The entire disclosure of all applications, patents and publications, cited above, and of corresponding French application No. 97.13502, are hereby incorporated by reference.

From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. 

1. A micromixer used in a continuous polymerization process for preparation of homopolymers or copolymers by free-impinging-jet micromixing of fluids formed (1) of monomer(s) and (2) of an initiator system, wherein said fluids (1) and (2) are micromixed and the mixture of these fluids is recovered in the form of a resultant jet Jr, originating from the point of impingement (I), the mixromixer comprising: a) means for forming at least one group of at least two jets Ja of identical or different fluids, these jets coinciding at a point of impingement (I), the jets Ja of the same group all being of identical geometry, their axes being arranged such that their projections on a plane perpendicular to the axis (A) of the resultant jet Jr are distributed angularly in a uniform manner and being inclined relative to the said axis (A) by the same non-zero angle α of between 10° and 60°; b) means for directing at the point of impingement (I) at least one jet Jb of a fluid which is different from at least one of the fluids of the said jets Ja for forming a resultant jet Jr, the axis of the jet(s) Jb being inclined relative to the axis (A) by an angle β which is less than the angle α, and c) means for recovering the mixture of the fluids in the jets Ja and Jb in the form of the resultant jet Jr.
 2. A device according to claim 1, wherein the means for forming the jets Ja and Jb comprise a nozzle holder (1) which holds as many nozzles (8, 11) as there are jets Ja and Jb, the nozzles being connected at the inletto fluid inlet tubes and being arranged and oriented to allow at their outlet the formation of the free jets Ja and Jb and the formation their point of impingement (I), and means for providing the necessary flow rates of the jets Ja and Jb; the means for recovering the mixture being a chamber (17) connected to the nozzle holder (1).
 3. A device according to claim 2, wherein the nozzles (8, 11) are removable to allow them to be exchanged with nozzles of different geometry.
 4. A device according to claim 2, wherein the nozzles (8, 11) are tubes of variable inside diameter or whose outlet end (11 a) is of variable inside diameter, or onto which distribution heads (9) of variable outlet diameter are fitted.
 5. A device according to claim 2 wherein the chamber (17) forms, with the nozzle holder (1), a reactor container for adjusting the temperature and pressure adjusting the temperature and pressure therein.
 6. A device according to claim 2 wherein the chamber (17) is cylindrical with a base which allows recovery of the jet Jr.
 7. A device according to claim 2, comprising: a first micromixing module formed of a first nozzle holder (1) and a first chamber (17), and a second mixromixing module formed of a second nozzle holder (101) connected to a second chamber (117), the second nozzle holder (101) containing an orifice (110) which allows passage of the jet Jr resulting from the micromixing in the first module, the jet Jr being used as a jet Jb for the micromixing in the second module. 